Advanced Structural Optimization Methods for AM Showcase

Efficient large-scale optimization of lattice structures for additive manufacturing (AM). Reduce weight and meet both engineering, material and AM requirements.

Description

Additive manufacturing (AM) enables multi-material fabrication of complex 3D objects, e.g. lattice structures, that are impossible to create with conventional manufacturing technologies and to design by hand. Adding multi-material capabilities, effectively designing structures and parts for optimized performance within the confines of AM constraints is highly challenging due to the vast potential design space and need to consider AM fabrication constraints directly while searching for...

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Additive manufacturing (AM) enables multi-material fabrication of complex 3D objects, e.g. lattice structures, that are impossible to create with conventional manufacturing technologies and to design by hand. Adding multi-material capabilities, effectively designing structures and parts for optimized performance within the confines of AM constraints is highly challenging due to the vast potential design space and need to consider AM fabrication constraints directly while searching for optimized designs. Material combination, e.g. from stiff to rubbery materials, and anisotropy in multi-material printing, e.g. Photopolymer Jetting, requires accurate material models developed through systematic testing of AM processes that are integrated in the optimization to generate performance optimized and functional designs.

We provide an approach for systematic testing of a multi-material photopolymer jetting printer and a new, advanced optimization method for large-scale optimization of multi-material lattice structures. Currently we support large-scale optimization for two different application scenarios: (1) the optimization of multi-material mesoscale lattice structures for displacement constraints and (2) optimized sizing of single material lattice structures with respect to material anisotropy, displacement, stress and Euler buckling constraints. Both methods are developed generically to accept models from any AM processes and ensure that the final design found by the algorithm can be directly fabricated without the need for post-processing.

Main features:

  • Systematic and efficient testing of AM material properties.
  • More efficient, large-scale optimization of discrete lattice structures.
  • Integration of experimentally tested material models for multiple digital materials on a Objet500 Connex3.
  • Multi-material mesoscale lattice structure optimization for minimum weight and displacement constraints.
  • Optimized sizing of single material lattice structures for minimum weight with respect to AM material anisotropy, displacement, stress and Euler buckling constraints.
  • WYSIWYG 3D printing, i.e. direct AM fabrication without the need for post-processing optimization results.

This showcase shows:

Process at customer

Major benefits achieved

Weight reduction

Field of innovation

Better products

Gallery

Customer

Internal Project

Customer position in the value chain

R&D + Organisations
Suppliers + Vendors
Processors + Service providers
Manufacturer (OEM)

Customer industry

Education / Research
Provider

Engineering Design and Computing Laboratory (EDAC), ETHZ

Supplier position in the value chain

R&D + Organisations
Suppliers + Vendors
Processors + Service providers
Manufacturer (OEM)
Technologies and materials

Technology

Materials

  • Plastic / Photopolymer
See this showcase

Engineering Design and Computing Laboratory (EDAC), ETHZ will display this showcase at the following exhibition:

AM Expo 2016
20. and 21. September 2016, Messe Luzern, Switzerland
Halle 02 / Booth Partnerzone